A hairspray carton is a printed sleeve around a pressurised metal can, and that changes the brief in two ways. The can dimensions are not yours to choose freely, and the transport rules belong to someone other than the packaging supplier. Everything else is a normal folding carton job. To order, see custom hairspray boxes.
The can decides the footprint
Aerosol cans are produced in a small set of standard diameters, commonly around 45, 52, 57 and 65 mm across the personal care category. Your filler runs particular sizes, so start by asking which can they are filling, then build the carton around it. A round can in a rectangular carton leaves four corner voids, which is normal and useful: they give the carton somewhere to flex during loading.
The overcap sets the height
Measure the can with its overcap fitted and fully seated, from the base to the top of the cap. A domed cap can add a surprising amount, and a carton sized to the bare can will bow at the top panel, which is the most visible packaging defect on a shelf. Add clearance so the tuck flap closes flat.
What to confirm before the carton is drawn
| Question | Who answers it |
|---|---|
| Which can diameter and height are being filled? | Your filler |
| Which overcap, and does it change between SKUs? | Your filler |
| How are cases palletised and how high do they stack? | Your warehouse or 3PL |
| What transport rules apply to your aerosol? | Your carrier and your regulatory advisor |
| Which required warnings appear on the carton? | Your regulatory advisor |
Board and coating
Hairspray cartons take handling in a bathroom and in a salon, so the outer surface matters. An aqueous coating resists scuffing at low cost; a laminate resists moisture better and gives a matte or gloss finish. Heavier caliper board resists the bowing that a tall narrow carton is prone to. Our guide to paperboard thickness covers the choice.
Carton style
Straight tuck end presents a clean front panel and is the usual retail choice. Reverse tuck is easier to hand pack. Seal end suits automated filling lines and gives a tamper evident closure. For tall cartons, check the dieline for panel-to-height ratio: a very tall narrow carton wants a heavier caliper or a locking flap to stay square. See tuck end boxes for the styles.
Transport is not a packaging claim
Pressurised aerosols are subject to transport rules that vary by carrier, mode and destination. Those rules govern how the product is shipped, not how the carton is printed, and we do not certify compliance for any of them. Settle the transport question with your carrier and your filler first, because it can dictate case count, case marking and labelling, all of which affect the artwork you are about to approve.
Ordering and turnaround
Minimum order is 100 cartons, from about $0.48 per unit at bulk volumes, confirmed on your written quote. The die, the plates, design support, US shipping and a digital proof before printing are included. We produce in West Chicago in the US and in Guangzhou in China. Three lanes are quoted per product: rush (expedited production plus air freight), standard (air) and cost saver (sea), from about 7 business days in production plus 2 to 5 days for delivery. For related formats, see custom hair product boxes.
Send your can diameter, capped height, artwork and quantity. Request a quote and we will return a carton size and a price.
